Introduction
Gone are the days of relying on human eyes for manufacturing inspections. In today’s fast-paced manufacturing, reducing errors is key to improving efficiency.
Today, manufacturing relies heavily on technology to automate every process. One integral component to achieving this goal is the vision system. These systems mimic human vision, enabling machines to inspect, measure, and guide processes.
But how do these systems work? Why are these camera systems conquering every assembly and quality control line? This blog will give you all the vital answers to what vision systems are in manufacturing.
What is a Vision System? How Is it Used in Manufacturing?
Ever wonder how robots in manufacturing can pick up products or materials on their own? Or how automated machines remove defective products from the assembly line? These independent functions begin with the machines’ ability to “see” objects via a camera system.
Those cameras you often see in the assembly line are vision systems in manufacturing. They have cameras, sensors, and software that capture and analyze images or videos. By mimicking the human vision, a machine can measure, inspect, and guide processes in an automated manner.
Thanks to this system, manufacturing has become more accurate and efficient. Today, you’ll see vision systems mostly in:
Quality Inspection
Detecting defects, inconsistencies, or anomalies in products.
Guidance and Positioning
Assisting robots in identifying parts and guiding assembly processes.
Sorting and Packaging
Automatically sorting products based on visual attributes and ensuring proper packaging.
Measurement
Providing precise measurements to ensure components meet specifications.
Types of Vision Systems Used in Manufacturing
Many types of vision systems exist to tailor to specific roles and functions. Here are the most common among all vision systems for manufacturing.
2D Vision System
A 2D vision system is dedicated to capturing images of flat, two-dimensional objects. They’re limited to analyzing basic features like shape, size, color, and orientation. You’ll find them often in tasks where the object does not have significant depth or complexity.
These tasks include:
- Surface defect detection
- Barcode reading
- Label inspection
3D Vision System
If you’re working with more complex objects, a 3D vision system is what you need. You rely on this type to measure an object’s depth, volume, and surface contours. This system uses specialized cameras or laser sensors to create detailed 3D images. It’s ideal for more complex applications with critical depth and spatial orientation. Examples include:
- Robotic part handling (grasping and sorting)
- Inspection of parts with complex geometries
- Measuring surface textures and contours
Line Scan Vision System
A line scan vision system captures images one line at a time as the object moves through the camera’s field of view. This type is perfect for inspecting long, continuous items, like sheets of paper, fabric, or wires, like that in a conveyor belt. It’s ideal for tasks that need high-resolution scanning in a linear fashion. Common applications include:
- Inspecting continuous materials (like textiles or metal sheets)
- Detecting defects in moving products
- Scanning and sorting long items
Area Scan Vision System
An area scan vision system takes a full image all at once using a grid of pixels to cover a wide area. It’s great for inspecting stationary objects and getting a detailed look at them. This system is perfect when you need to see a larger field simultaneously. It’s often used in situations where high-quality, detailed images are needed. Some examples include:
- Checking products on assembly lines
- Inspecting flat objects like labels or packaging
- Reading barcodes on still products
Intelligent Vision System
An intelligent vision system goes further by using smart algorithms and machine learning. It doesn’t just capture images – it can also make decisions based on the data. These systems can look at images in real-time and adjust to changes without needing a human to step in. They’re ideal for situations where things are always changing, and you need something precise. Some examples include:
- Robots that sort and move things on their own
- Quality control that makes decisions based on what it sees
- Monitoring equipment to predict when it might need maintenance
Application of Vision Systems in Manufacturing
As early as the 1950’s, some facilities already use vision systems, or what’s called machine vision, at times. But only in the years between the 1980s-1990s do these systems really expand. Today, they remain a central piece in every manufacturing facility. Their technological upgrades have already been significant since those times. And like their tech integrations, their applications has already expanded.
Quality Inspection
Vision systems are like supercharged quality control inspectors. They’re great at catching defects or issues with products. Some advanced systems can detect even the smallest flaw in an object, like scratches or dents. This means problems get spotted immediately and fixed before they’re sorted for delivery. With this, manufacturers can prevent defective products from reaching the market. This way, a company can protect its brand and remain standards-compliant.
Barcode and Label Reading
Barcode readers may not be the earliest vision systems developed, but they are one of the oldest. Until today, barcode and label reading systems remain central to manufacturing. They make inventory management less complicated and undeniably convenient.
These machine visions are very popular even outside the manufacturing facility. They make sorting, storing, and tracking products more organized.
Guidance and Positioning
Automated robots are becoming more and more the standard in manufacturing. However, without vision systems, such innovation will not thrive. It’s the vision systems that give “eyes” to robots and ensure they function as they should. They give real-time feedback so robots can spot objects and ensure they’re in the right place. Whether it’s putting together a product or moving parts around, these systems help machines become as error-free as possible.
Sorting and Packaging
Vision systems make sorting and packaging products super easy. They quickly check size, shape, and color and sort items accordingly. This cuts down on mistakes, speeds up the process, and ensures everything’s packaged just right. It’s like having a highly organized helper who never gets tired and always gets the job done right.
Measurement
In manufacturing, precision is key. Vision systems measure parts to make sure they meet exact specs. Whether it’s checking the length or thickness of a part, these systems provide accurate and adjust measurements instantly. This eliminates the need for manual tools that are rather slow and prone to inaccuracies.
Benefits of Using Vision Systems
In 2023, the global vision systems market was worth a staggering $49.7 billion. Market forecasts expect this market size to triple in the next eight years. These numbers are a clear sign of how valuable vision systems are.
But these numbers shouldn’t be a surprise at all. These systems are poised to dominate every industrial space for an array of good reasons. Beyond speeding things up, vision systems offer other benefits.
Improved Quality Control:
Vision systems are incredibly precise at spotting defects invisible to the naked eye. They ensure consistent product quality control that’s hard to achieve manually in manual quality checks.
Increased Efficiency:
Vision systems inspect products rapidly, preventing congestion or sluggishness in the production line. When speed is guaranteed without compromise, you get unmatched efficiency.
Cost Reduction:
Vision systems cut human labor costs and avoid defects. They eliminate manual labor, eliminating human errors and amplifying production speed. These conditions set the stage for lower operational costs while boosting productivity.
Enhanced Flexibility:
Vision systems can easily adapt to different products and tasks. This allows manufacturers to switch between tasks without impractical downtime. This offers versatile solution for many applications and roles.
Better Data Collection and Analysis:
Vision systems not only allow real-time monitoring but also store data for future analysis. These vital information can help improve processes and identify weaknesses in the system or work. These data can help make informed and calculated decisions on the manufacturing floor.
Improved Safety:
Occupational safety was a major threat to human workers before. However, with machine automation, facilities can significantly reduce accidents in the workplace. By automating the inspection process, vision systems can handle hazardous tasks. Now, you can end the risk of exposing workers to direct risks and hazards.
MXP: Your Trusted Manufacturer of Industrial Vision Measurement Machines
Vision systems are so beneficial in many ways. With the way they change manufacturing processes, investing in them is no longer a mere option. It’s now a MUST to stay afloat in the ever-competitive manufacturing space.
But investing in a vision system of any scale isn’t to be taken lightly. One reason is because it’s not a cheap investment. And most importantly, you can only maximize its benefits if you get quality systems that guarantee the best performance.
At MXP, we develop premium, world-class vision measuring systems. It is our commitment to provide precision measurement solutions for various industrial spaces. Our goal is to provide accurate, reliable and affordable solutions.
Connect with us at MXP today and see why we should be your number #1 choice!